marble waste utilization in pakistan- the practices and few options
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Current Scenario An indication of Marble and Granite in AJK, G.B., and Sind, but the available data and mining activities are limited to the Province of Balochistan and KP.
Balochistan though contributes less in quantity, but still important due to its export quality Onyx (Shades of Green, Red, and White), and Marble (Black and Gold, Boticina, Burma teak, Chocolate, Tippi, Travera, and Verona). (Source: Industry Survey)
The KP dominates the production of Marble (Ziarat White, Nowshehra Pink, Sunny, and Jet Black), and Granite (Mostly Black). (Source: Industry Survey)
The reputed marble from Sind is that of the Indus Gold, and some shades of Granite. (Source: Industry Survey)
160 Million Tons of Marble Reserves estimated (158 Million Tons in KP, and 2 Million Tons in Balochistan). (Source: SMEDA, Mineral Statistics of Pakistan, Industry Survey)
The estimated reserves of Granite are 5,676 Million Tons (Out of which 4,140 Million Tons are estimated in Northern Areas). (Source: SMEDA, Mineral Statistics of Pakistan Industry Survey)
Current ScenarioThis point Onwards the word Marble and Granite is used for simplicity. The production of Marble and Granite during the year 2011-12 was 1.07 Million
Tons (Pakistan’s Statistical Year Book) . Referring to the general wastage in mining and processing of around 70%
(SMEDA, and Industry Survey), the estimated wastage is 0.75 Million Tons This wastage means the loss of over Rs. 7.5 Billion
Marble Processing Practices in Pakistan
Balochistan and Sind
Squared Blocks
Block Squaring
Solid Waste
Balochistan, KP, Punjab, and Sind
Slabs
Slab Sawing (Gang-Saw)
StripsSolid Waste
Vertical Cutting/HV Cutting)
Balochistan/Sind:Strips/Thick Tiles (Gutka- 14 Soot Thick)
Solid Waste
Balochistan, KP, and Sind
KP:Strips/Thick Tiles (Gutka- 09 Soot Thick)
Section Cutting)Strips/Thick Tiles (4 Soot, 1cm, 1.2 cm
Thick)
Solid Waste
Balochistan, KP, Punjab, and Sind
Squared Blocks
Products of a Complete Processing Units
Irregular Shaped Slabs Proper Slabs
Polished Strips Polished and Unpolished Tiles Unpolished Strips/Tiles of Different Dimensions
Solid Waste of a Complete Processing Units
Marble Slurry Water
General Condition for All Processing Units
Marble Sludge
Solid Waste from BlocksThe onyx waste is sold to the handicrafts manufacturers against a handsome amount whereas that of the marble waste depends upon the hardness and color of the stone. The beige color soft marble stones are sold to the section machine owners for production of small tiles. Contrary to this, the Black and Gold, and Burmateak waste is thrown away by the blocks processors. Recently, a factory at Marble City, Gadani of Balochistan has started collection and crushing of this waste into cobbles as a replacement for river stone crush.
Solid Waste from TilesIn case of Onyx the wastage during processing is purchased by the mosaic manufactures, and the wastage is negligible. The real issue is that of the marble tiles waste. The way it is dealt with differs from province to province. In Balochistan a major portion goes to the land fills of nearby barren lands and a small quantity is collected free of charges by the local people using it in housing foundations filling. In Karachi and Punjab, this mostly remained dumped on roadsides in industrial or even residential areas. In KP, this scrape is sold to the people at Rs. 1,000 per ton for house landfills purpose.
In the Marble City, Gadani of Balochistan, the newly established tiles processing units utilize such waste for filling of the depressed portions of their factories and also use it for boundary walls.
Marble Slurry WaterThroughout the country, the marble slurry is currently going unutilized to landfills, which not only costs Rs. 4,000 to Rs. 9,000 per month to the processors against waste disposal but also poses a serious environmental threat.
Marble Waste Utilization
Waste Utilization: Current Practices
Boundary Walls
Talya: Solid Waste From Block Squaring
Waste Utilization: Current Practices
Beige Color Marble into Tiles of (1’x1’) and (05’x1’)
Black and Gold and Dolomite into Crush
Processing Waste/Mine Handpicks
Waste Utilization: Current Practices
Onyx Handicrafts
Onyx into Handicrafts
Source: Suppliers of Onyx Products
Waste Utilization: Current Practices
Onyx and Marble Mosaics Talya Cutting into Tiles of 12” x 12”, and 6” x 12”
and then Tesserae Hand Pick Cutting Into Strips and then Tesserae Wasted Tiles Cutting Into Strips and Tesserae
Chips and Powder Processing
General Utilization- Current Practices
Marble/Onyx Chips
Marble and Onyx into Chips/Terrazo and Powder
Marble Powder
Source: Suppliers of Chips and Powder
Processing Waste
Suggested Utilization of Larger Sized Waste
Pakistani Machine
Processing Waste
Currently Working Upon the Possibility of
Inlays*
* A picture downloaded from : http://www.monarchcrafts.com/
Vibro Press Machine
Suggested Utilization of Slurry/Sludge Waste
Source: UNIDO Document
Marble Slurry Bricks